Infrared sensor design using an epoxy film as an infrared absorption layer
A MEMS IR sensor, with a cavity in a substrate underlapping an overlying layer and a temperature sensing component disposed in the overlying layer over the cavity, may be formed by forming an IR-absorbing sealing layer on the overlying layer so as to cover access holes to the cavity. The sealing layer is may include a photosensitive material, and the sealing layer may be patterned using a photolithographic process to form an IR-absorbing seal. Alternately, the sealing layer may be patterned using a mask and etch process to form the IR-absorbing seal.
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This application is a divisional of U.S. Nonprovisional patent application Ser. No. 13/411,849, filed Mar. 5, 2012 which claims the benefit of priority under U.S.C. § 119(e) of U.S. Provisional Application 61/449,296 (filed Mar. 4, 2011) the contents of both of which are hereby incorporated by reference.
The following co-pending patent applications are related and hereby incorporated by reference:
U.S. patent application Ser. No. 13/411,861 (filed Mar. 5, 2012) entitled “CAVITY PROCESS ETCH UNDERCUT MONITOR,”
U.S. patent application Ser. No. 13/411,871 (filed Mar. 5, 2012) entitled “CAVITY OPEN PROCESS TO IMPROVE UNDERCUT,”
U.S. patent application Ser. No. 13/412,562 (filed Mar. 5, 2012) entitled “BACKGROUND PROCESS FOR INTEGRATED CIRCUIT WAFERS,” and
U.S. patent application Ser. No. 13/412,563 (filed Mar. 5, 2012) entitled “SENSOR COVER FOR INTEGRATED SENSOR CHIPS.”
FIELD OF THE INVENTIONThis invention relates to the field of microelectronic mechanical systems (MEMS) devices. More particularly, this invention relates to three-dimensional structures in MEMS devices.
BACKGROUND OF THE INVENTIONA microelectronic mechanical system (MEMS) infrared (IR) sensor may have a cavity in a substrate underlapping an overlying layer. A temperature sensing component may be disposed in the overlying layer over the cavity, so that the cavity provides thermal isolation between the temperature sensing component and the substrate. It may be desirable to prevent foreign material from entering the cavity, for example through an access hole in the overlying layer, during fabrication steps of the IR sensor subsequent to forming the cavity.
SUMMARY OF THE INVENTIONThe following presents a simplified summary in order to provide a basic understanding of one or more aspects of the invention. This summary is not an extensive overview of the invention, and is neither intended to identify key or critical elements of the invention, nor to delineate the scope thereof. Rather, the primary purpose of the summary is to present some concepts of the invention in a simplified form as a prelude to a more detailed description that is presented later.
A MEMS IR sensor, with a cavity in a substrate underlapping an overlying layer and a temperature sensing component disposed in the overlying layer over the cavity, may be formed by forming an IR-absorbing sealing layer on the overlying layer so as to cover access holes to the cavity. The sealing layer is subsequently patterned using a photolithographic process and possibly an etch process to form an IR-absorbing seal which prevents foreign material from entering the cavity.
The present invention is described with reference to the attached figures. The figures are not drawn to scale and they are provided merely to illustrate the invention. Several aspects of the invention are described below with reference to example applications for illustration. It should be understood that numerous specific details, relationships, and methods are set forth to provide an understanding of the invention. One skilled in the relevant art, however, will readily recognize that the invention can be practiced without one or more of the specific details or with other methods. In other instances, well-known structures or operations are not shown in detail to avoid obscuring the invention. The present invention is not limited by the illustrated ordering of acts or events, as some acts may occur in different orders and/or concurrently with other acts or events. Furthermore, not all illustrated acts or events are required to implement a methodology in accordance with the present invention.
A MEMS IR sensor, with a cavity in a substrate underlapping an overlying layer and a temperature sensing component disposed in the overlying layer over the cavity, may be formed by forming an IR-absorbing sealing layer on the overlying layer so as to cover access holes to the cavity. The sealing layer is subsequently patterned using a photolithographic process and possibly an etch process to form an IR-absorbing seal which prevents foreign material from entering the cavity. The MEMS IR sensor may have an optional second temperature sensing component disposed in the overlying layer over the substrate adjacent to the cavity, and configured in a differential mode with the temperature sensing component disposed over the cavity, so that a sensor circuit in the MEMS IR sensor measures a temperature difference between the two temperature sensing components. The MEMS IR sensor may be used to detect a hot object emitting IR energy. The temperature sensing component disposed over the cavity has a higher thermal impedance to the substrate than the second temperature sensing component disposed over the substrate adjacent to the cavity. Disposing the IR-absorbing seal over the temperature sensing component provides that more IR energy from the hot object will be transferred to the temperature sensing component than to the second temperature sensing component. The combination of more IR energy transferred to the temperature sensing component and the higher thermal impedance to substrate for the temperature sensing component provides a higher temperature at the temperature sensing component than at the second temperature sensing component. Thus, the sensor circuit will measure a temperature difference related to the IR energy from the remote source.
For the purposes of this description, the term “substantially” is understood to mean within fabrication tolerances and irrespective of variations encountered during fabrication of embodiments.
An IR-absorbing seal 112 is formed over the overlying dielectric layer 104 so as to cover the access holes 106. The IR-absorbing seal 112 may be, for example, 10 to 20 microns thick, and absorbs at least 50 percent of infrared energy incident on the IR-absorbing seal 112 in a wavelength band of 8 to 10 microns. The IR-absorbing seal 112 includes organic polymer material, for example epoxy, which is resistant to strong solvents and oxidizing chemicals used in subsequent processing steps, such as plating mask removal and plating seed layer removal, and possibly filler material with high IR absorbing properties, such as carbon particles. The IR-absorbing seal 112 may possibly not extend to lateral edges of the cavity 108, may possibly be approximately coincident with the lateral edges of the cavity 108 as depicted in
The overlying dielectric layer 104 may also contain an input/output (I/O) pad 114. A plated I/O bump 116 which includes a bump seed layer 118, a plated copper bump 120 and a plated metal cap layer 122 is formed on the I/O pad 114. The plated I/O bump 116 may be formed after the IR-absorbing seal 112 is formed.
Forming the IR-absorbing seal 112 so as to cover the access holes 106 may advantageously prevent foreign material from entering the cavity 108 during subsequent process steps such as singulation, in which adjacent instances of the MEMS IR sensor 100 are separated, commonly by sawing in the presence of a water stream. Forming the IR-absorbing seal 112 to absorb at least 50 percent of infrared energy incident on the IR-absorbing seal 112 in a wavelength band of 8 to 10 microns may advantageously improve a sensitivity of the MEMS IR sensor 100 to a desired value. Forming the IR-absorbing seal 112 to include organic polymer material which is resistant to solvents used in subsequent processing steps may advantageously improve a fabrication yield of the MEMS IR sensor 100.
The MEMS IR sensor 100 may include an optional second temperature sensing component 124 disposed over the substrate 102 adjacent to the cavity 108, so that the first temperature sensing component 110 has a larger thermal impedance to the substrate 102 than the second temperature sensing component 124. More IR energy from a remote source such as a hot object may be absorbed by the IR-absorbing seal 112 than by materials proximate to the second temperature sensing component 124, so that the first temperature sensing component 110 may have a higher temperature than the second temperature sensing component 124. A sensor circuit connected in a differential mode to the first temperature sensing component 110 and the second temperature sensing component 124 will measure a temperature difference related to an amplitude of the IR energy from the remote source.
During formation of the overlying dielectric layer 104, the temperature sensing component 110 is formed in or on the overlying dielectric layer 104. Additionally, metal interconnect lines may be formed in the overlying dielectric layer 104, for example to connect the temperature sensing component 110 to circuitry in the MEMS IR sensor 100. The optional I/O pad 114 may be formed during formation of the overlying dielectric layer 104.
The access holes 106 are formed through the overlying dielectric layer 104 proximate to the temperature sensing component 110, for example by forming an access hole etch mask over the overlying dielectric layer 104 and performing an access hole etch process which removes material from the overlying dielectric layer 104 so as to expose the substrate 102. The access hole etch process may include one or more reactive ion etch (RIE) steps which provide fluorine ions and other reactants into the access holes 106. If the optional I/O pad 114 is present, an I/O opening 126 which exposes the I/O pad 114 may be formed concurrently with the access holes 106.
The cavity 108 is formed in the substrate 102 by a cavity etch process performed after the access holes 106 are formed. The cavity etch process may be formed using a process sequence of forming a cavity etch mask over the overlying dielectric layer 104 which exposes the substrate 102 in the access holes 106 and exposing the MEMS IR sensor 100 to an isotropic ambient containing etchant species such as halogen radicals. The access hole etch mask may possibly be used for the cavity etch mask. The cavity 108 underlaps the access holes 106 by at least 5 microns.
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After formation of the IR-absorbing seal 112, the plated I/O bump 116 of
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An IR-absorbing sealing layer 326 is formed over the overlying dielectric layer 304, covering the access holes 306. The IR-absorbing sealing layer 326 has a layered structure and includes an adhesive material 336 such as epoxy contacting the overlying dielectric layer 304, an IR absorbing material 338 such as carbon particle impregnated epoxy, and possibly an optional overcoat layer 340 such as epoxy or polyimide at a top surface of the IR-absorbing sealing layer 326. The IR absorbing material 338 absorbs at least 50 percent of infrared energy incident on the IR-absorbing sealing layer 326 in a wavelength band of 8 to 10 microns. The IR-absorbing sealing layer 326 may be applied to the overlying dielectric layer 304, for example, as described in reference to
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After formation of the IR-absorbing seal 312, a plated I/O bump may be formed on the I/O pad 314, if present, for example using the process sequence described in reference to
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While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only and not limitation. Numerous changes to the disclosed embodiments can be made in accordance with the disclosure herein without departing from the spirit or scope of the invention. Thus, the breadth and scope of the present invention should not be limited by any of the above described embodiments. Rather, the scope of the invention should be defined in accordance with the following claims and their equivalents.
Claims
1. A microelectronic mechanical system (MEMS) infrared (IR) sensor, comprising:
- a substrate;
- an overlying dielectric layer disposed over said substrate, with access holes through said overlying dielectric layer;
- a cavity in said substrate under said access holes;
- a first temperature sensing component disposed over said cavity; and
- an IR-absorbing seal disposed over said overlying dielectric layer so as to cover said access holes without extending into said cavity, said IR-absorbing seal including:
- an adhesive material contacting the overlying dielectric material;
- an IR-absorbing material on the adhesive material; and an overcoat layer over the IR-absorbing material; and
- wherein the IR-absorbing seal does not extend past the lateral edges of the cavity.
2. The MEMS IR sensor of claim 1, further including a plated input/output (I/O) bump, said plated I/O bump including:
- a bump seed layer making electrical connection to an I/O pad disposed in said overlying dielectric layer through an I/O opening in said overlying dielectric layer;
- a plated copper bump disposed on said bump seed layer; and
- a plated metal cap layer disposed on said plated copper bump.
3. The MEMS IR sensor of claim 1, wherein the IR-absorbing material is adapted to absorb at least 50 percent of infrared energy incident on said IR-absorbing seal in a wavelength band of 8 to 10 microns.
4. The MEMS IR sensor of claim 1, wherein the adhesive material comprises an epoxy.
5. The MEMS IR sensor of claim 1, wherein the IR absorbing material is a carbon particle impregnated epoxy.
6. The MEMS IR sensor of claim 1, wherein the overcoat layer comprises polymide.
7. The MEMS IR sensor of claim 1, wherein the overcoat layer comprises an epoxy.
8. A microelectronic mechanical system (MEMS) infrared (IR) sensor, comprising:
- a substrate;
- an overlying dielectric layer disposed over said substrate, with access holes through said overlying dielectric layer;
- a cavity in said substrate under said access holes; a first temperature sensing component disposed over said cavity a second temperature sensing component disposed over a portion of the substrate not including the cavity; and
- an IR-absorbing seal disposed over said overlying dielectric layer so as to cover said access holes without extending into said cavity, wherein the IR-absorbing seal is located over the first temperature sensing component and not over the second temperature sensing component, the IR-absorbing seal comprising: an adhesive material contacting the overlying dielectric material; an IR-absorbing material on the adhesive material; an overcoat layer over the IR-absorbing material; and wherein the IR-absorbing seal does not extend past the lateral edges of the cavity.
9. The MEMS IR sensor of claim 8, wherein the substrate is silicon.
10. The MEMS IR sensor of claim 9, wherein the IR absorbing material is a carbon particle impregnated epoxy.
11. The MEMS IR sensor of claim 10, wherein the adhesive material comprises an epoxy.
12. The MEMS IR sensor of claim 11, wherein the overcoat layer comprises an epoxy.
13. The MEMS IR sensor of claim 11, wherein the overcoat layer comprises polyimide.
14. The MEMS IR sensor of claim 8, further including a plated input/output (I/O) bump, said plated IO bump including: a bump seed layer making electrical connection to an I/O pad disposed in said overlying dielectric layer through an I/O opening in said overlying dielectric layer; a plated copper bump disposed on said bump seed layer; and a plated metal cap layer disposed on said plated copper bump.
15. The MEMS IR sensor of claim 8, wherein the IR-absorbing material is adapted to absorb at least 50 percent of infrared energy incident on said IR-absorbing seal in a wavelength band of 8 to 10 microns.
16. The MEMS IR sensor of claim 8, wherein the temperature sensing component includes Seebeck junctions.
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Type: Grant
Filed: Mar 2, 2017
Date of Patent: Feb 25, 2020
Patent Publication Number: 20170174505
Assignee: TEXAS INSTRUMENTS INCORPORATED (Dallas, TX)
Inventors: Ricky Alan Jackson (Richardson, TX), Walter Baker Meinel (Tucson, AZ), Kalin Valeriev Lazarov (Tucson, AZ), Brian E. Goodlin (Plano, TX)
Primary Examiner: Matthew C Landau
Assistant Examiner: Priya M Rampersaud
Application Number: 15/447,932
International Classification: B81B 7/00 (20060101); H01L 27/144 (20060101); B81C 1/00 (20060101);